4. Cable
4.1 Replacing Cable Unit
Since the power is supplied to each motor from the lithium battery installed on the battery board via the battery connector, the position data will not be lost when the Controller is turned OFF. When the battery connectors are disconnected, the position data will be lost, and EPSON RC+ will display an error when the Controller is turned ON.
If the error occurs, execute the calibration of all joints and axes.
For details of the calibration, refer to Maintenance: 13. Calibration.
Name Quantity Note
Maintenance parts
Cable unit 1 Each manipulator model
(Refer to Maintenance:
14. Maintenance parts)
Battery Unit (Lithium battery) 1 R13ZA00600300
Tools
Hexagonal wrench
width across flats: 3 mm 1 For M4 screw width across flats: 4 mm 1 For M5 screw width across flats: 5 mm 1 For M6 screw
Spanner width across flats: 5 mm 1 For D-sub connector removal Nut screwdriver width across flats: 5 mm 1 For D-sub connector removal
Nippers 1 For cutting wire tie
Alcohol Proper
quantity For wiping grease
Wiping cloth 1 For wiping grease
Material Wire tie 9
Grease Grease for cable (GPL-224)
Maintenance 4. Cable
Table Top mounting
Cable Unit
Wall mounting
Cable Unit
Ceiling mounting
Cable Unit
Maintenance 4. Cable
G6 Rev.21 109
CAUTION
■ If the connectors have been disconnected during the replacement of the cable unit, be sure to reconnect the connectors to their proper positions. Refer to the block diagrams.
Improper connection of the connectors may result in improper function of the robot system.
For details on the connections, refer to Maintenance: 4.2 Wiring Diagrams.
■ When installing the cover, be careful not to allow the cables to interfere with the cover mounting and do not bend these cables forcibly to push them into the cover. Unnecessary strain on cables may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system.
When routing the cables, observe the cable locations after removing the cover.
Be sure to place the cables back to their original locations.
■ Be sure to connect the cables properly. Do not allow unnecessary strain on the cables. (Do not put heavy objects on the cables. Do not bend or pull the cables forcibly.) The unnecessary strain on the cables may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system.
Cable unit Removal
(1) Turn ON the Controller and change the motor to OFF status (MOTOR OFF).
(2) Press and hold the brake release switch to let the shaft down. Be sure to keep enough space and prevent the end effector hitting any peripheral equipment.
The brake release switch affects both Joints #3 and #4. When the brake release switch is pressed, the brakes for both Joints #3 and #4 are released simultaneously.
(Joint #4 brake is installed to G6-**3** only.)
Be careful of the shaft falling or rotation while the brake release switch is being pushed because it may be lowered by the weight of an end effector.
(3) Turn OFF the Controller and disconnect the power cable and signal cable connectors from thee controller.
(4) Remove the connector plate.
For details, refer to Maintenance: 3.4 Connector Plate.
(5) Connect the spare battery to connector XB11.
- The position data of Joint #1 motor is stored with the battery on Arm #2.
Connect the spare battery otherwise the Joint #1 position data will be lost.
(6) Disconnect the connectors, air tubes, ground wire, D-sub cable, and seven connectors (X10, X20, X30, X111, X121, X131, XB10) connected to the connector plate (inner side).
- Remember the cable layout so that the cables can be reconnected correctly after replacement.
(7) The procedure of step (7) differs by mounting types.
Follow the corresponding procedure.
NOTEMaintenance 4. Cable
When using Table Top mounting type or Ceiling mounting type (7)-1 Remove the saddle part mounting
cables inside the base.
(7) 2-M4×10 Saddle part Wire tie (8) 2-M4×10
Spring plate (7)-2 Remove the spring plate.
(7)-3 Cut off the two wire ties binding cables.
When using Wall mounting type (7)-1 Remove the ground plate.
2-M4×10
Ground plate
(7)-2 Remove the spring plate.
2-M4×10 Spring plate
(7)-3 Cut the wire tie banding the cables. Wire tie
(7)-4 Pull out the spring plate. Spring plate
(7)-5 Remove the saddle part mounting the cables.
2-M4×10
Saddle part (7)-6 Cut the wire tie banding the spring.
Maintenance 4. Cable
G6 Rev.21 111
(8) Remove the arm caps and side covers on Arm #1.
For details, refer to Maintenance: 3.3 Arm #1 Cover.
(9) Remove the arm top cover.
For details, refer to Maintenance: 3.1 Arm Top Cover.
(10) Remove the user plate.
For details of user plate removal, refer to Maintenance 3.6 User Plate.
(11) Disconnect the D-sub cable, air tubes, and connector of the brake release switch from the user plate.
Mounting screws for the D-sub cable are very small. Be sure to keep the screws.
Press the ring on the fitting and pull out the air tube. (ø6×2, ø4×2)
D-sub cable
Air tube Brake release switch cable Be sure to observe the connection for connecting the disconnected parts after replacement.
(12) Cut off the wire tie binding cables on the Arm
#2 side. Wire tie
(13) Remove the 11 connectors on the Arm side.
X21, X22, X31, X32, X33, X41, X42, X61, X221, X231, X241
Be sure to keep the connectors excluding X61 of the battery board connected at cables replacement. Otherwise, the motor will lose position data and the calibration must be executed again.
(14) Remove the ground terminals mounted to Arm
#2.
Record the connection terminal and the connection point before disconnect the ground terminal.
G6-***S*, C*: 2 terminals G6-***D*, P*: 3 terminals
Ground terminal
(15) Remove the saddle part mounting cables inside Arm #2. (16) Remove the spring plate.
(17) Cut off the wire ties binding cable and fixing spring.
NOTE
NOTE
NOTEMaintenance 4. Cable
(18) Disconnect the Base side cables from Arm #1.
Table Top mounting
: Disconnect from the upper part of Arm #1 Wall mounting, Ceiling mounting
: Disconnect from the lower part of Arm #1 When disconnecting the cables, first, disconnect the air tubes. Then, disconnect from the smaller connectors in order.
Do not try to disconnect the cables forcibly.
Otherwise, connectors may be stuck, disconnected, or connector pins may fall off.
Cable Table Top mounting
Cable Wall / Ceiling mounting
(19) Disconnect the cables that were disconnected from Arm #1 in step (18) to the side of Arm #1.
Cable Table Top mounting
Cable Wall / Ceiling mounting
(20) Disconnect the Arm #2 side cables from the lower part of Arm #1.
When disconnecting the cables, first, disconnect the air tubes. Then, disconnect from the smaller connectors in order.
Do not try to disconnect the cables forcibly.
Otherwise, connectors may be stuck, disconnected, or connector pins may fall off.
Cable
(21) Disconnect the cables that were disconnected to the lower part of Arm #1 in step (20) to the side of Arm #1.
Cable
(22) Remove the Arm #1 four mounting bolts on the spring plate side.
4-M6×15 (23) Disconnect the cables to the base side.
NOTE
NOTEMaintenance 4. Cable
G6 Rev.21 113
Cable unit Installation
(1) Apply grease (GPL-224) to the cables.
Grease volume: 5 g each (10 g in total)
Each cable inside the spring Air tube
Periphery of spring (shaded part)
(2) Cover both ends of the cables with plastic bags.
(The photo shows one end covered with plastic bags)
The plastic bags prevent grease adhesion to the ends of connectors and air tubes during the cable drawing.
(4) Set the mounting holes of the spring plate to the base side and mount the spring plate to Arm #1.
4-M6×15 (5) When using Table Top mounting, disconnect the
base side cables to the upper part of Arm #1 and pull the cables into the base.
When using Wall mounting or Ceiling mounting, disconnect the base side cables to the lower part of Arm #1 and pull the cables into the base.
Cable Table Top mounting
Cable Wall / Ceiling mounting
(6) The procedure of step (6) differs by mounting types.
Follow the corresponding procedure.
Maintenance 4. Cable
When using Table Top mounting type or Ceiling mounting type (6)-1 Mount the spring for cable protection to
the spring plate with a wire tie.
Spring plate Wire tie Spring
(6)-2 Mount the spring plate to the base. 2-M4×10
Spring plate
(6)-3 Move Arm #1 to the right or left until the arm touches the mechanical stop to make allowance.
Then, band the cables and air tubes with a wire tie.
If you band the cables and tubes without allowance, the cables are pulled and may be disconnected during the robot operation. Make sure to make allowance.
Wire tie
(6)-4 Remove the plastic bags on the base side applied in step (2).
(6)-5 Mount the saddle part to the spring plate.
2-M4×10 Saddle part Spring plate
NOTEMaintenance 4. Cable
G6 Rev.21 115
When using Wall mounting type
(6)-1 Pull out the spring and mount it to the spring plate with a wire tie.
(6)-2 Mount the saddle part to mount the cables.
2-M4×10
Saddle part
(6)-3 Loosely band the cables with a wire tie.
Be sure to keep the wire tie loose enough so that the cables move.
Spring plate
(6)-4 Move Arm #1 to the right or left until the arm touches the mechanical stop to make allowance. Then, band the cables and air tubes with a wire tie.
If you band the cables and tubes without allowance, the cables are pulled and may be disconnected during the robot
operation. Make sure to make allowance.
Wire tie
(6)-5 Remove the plastic bags on the base side applied in step (2).
(6)-6 Mount the spring plate.
2-M4×10 Spring plate
(6)-7 Mount the ground plate.
2-M4×10
Ground plate
NOTEMaintenance 4. Cable
(7) Connect the connectors, air tubes, D-sub cable, and connectors to the connector plate (inner side).
Connector
D-sub
D-sub cable
Air tube Nut
Ground terminal Plain washer
Spring washer
Connector plate
(8) Loosely mount the connector plate with two screws (M4).
For details, refer to Maintenance: 3.4 Connector Plate.
(9) Disconnect the Arm #2 side cables to the lower part of Arm #1 and pull the cables into Arm #2.
Cable
(10) Mount the spring for cable protection to the spring plate with a wire tie.
Secure the spring plate to Arm 2.
Wire tie
Spring plate Spring
(11) Move Arm #2 until the arm touches the mechanical stop to make allowance.
Then, band the cables and air tubes with a wire tie.
If you band the cables and tubes without allowance, the cables are pulled and may be disconnected during the robot operation. Make sure to make allowance.
Wire tie
(12) Remove the plastic bags on the Arm side applied in step (2).
NOTEMaintenance 4. Cable
G6 Rev.21 117
(13) Mount the saddle part to the spring plate.
2-M5×10 Saddle part
(14) Connect the connectors and the ground wire.
For details, refer to Maintenance: 4.2 Wiring Diagrams.
(15) Bind the excess cables with a wire tie.
(16) Connect the D-sub cable, air tubes, and connector of the brake release switch cable to the user plate.
D-sub cable
Air tube Brake release switch cable (17) Mount the user plate to the Arm #2 cover.
For details of user plate installation, refer to Maintenance 3.6 User Plate.
(18) Set and secure the Arm #2 cover without the cables being stuck.
For details, refer to Maintenance: 3.1 Arm Top Cover.
(19) Mount the arm caps and side covers for Arm #1.
For details, refer to Maintenance: 3.3 Arm #1 Cover.
(20) Remove the conector plate mounted loosely in the step (8) and remove the spare battery in theXB11. Then, mount the connector plate.
In this replacement method, calibration is not needed.
However, perform the calibration if it is required.
NOTEMaintenance 4. Cable